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Motor Repair
Electrical Engineering
Maintenance

MotorAnalyzer-Class
Motor Repair
The MotorAnalyzer-Class
Unbeatable versatility

MotorAnalyzer 2 |
All-purpose electric motor tester ..................................... 24
MotorAnalyzer 1 |
All-purpose electric motor tester ..................................... 28
Product and accessory overview ..................................... 32

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 The MotorAnalyzer-Class
MotorAnalyzer 2 | All-purpose electric motor tester

USB
PC
I/O

The all-purpose MotorAnalyzer 2 serves for checking electric

Highlights motors and winding goods. It combines eleven different test
• 11 test methods methods within a user-friendly and mobile tester. The
• surge voltage up to 3000V combination of test methods, its extremely compact design, as
well as the battery operation turn the MotorAnalyzer into an ideal
• high-voltage DC up to 6000V
tool for the on-site operation, especially in difficult installation
• large, very well-readable color display
positions.
• innovative handy input via rotary button
• structured menu and practical functioning buttons For checking a 3-phase motor the three winding connections and
• fully-automatic fault analysis the motor’s cabinet are connected to the tester. This should be
• automatic switchover between the three motor connecting leads performed in four-wire technology for a high-precise resistance
• manual and automatic tests measuring. Afterwards the MotorAnalyzer analyzes the motor
• locating turn-to-turn faults fully-automatically via surge-voltage, resistance, and inductivity
• adjusting the neutral zone test. For this the MotorAnalyzer automatically switches the
• rotary button for a quick test method selection different test methods to the four measuring points one after
• integrated result storage for a subsequent transfer via another via its internal relay matrix. After this the motor is also
USB-interface tested automatically with a high-voltage test in order to evaluate
the motor’s quality quickly and clearly.
• storing and printing of test results via PrintCom
• network or battery operation
In addition to the motor test the MotorAnalyzer also assists in
• worldwide voltage supply 110V…250V / 47…63Hz
adjusting the brush holder at DC motors as well as in locating
• low weight turn-to-turn faults.
• all-purpose solid case including all measuring leads “on board”
The very compact case is sturdy and waterproof. On the
right-hand side of the operating element there is a storage space.
All measuring leads and test probes are stored here. Thus the
operator can always access the necessary components during the
measuring. For an optimum operator guidance the LEDs indicate
the measuring leads that are activated for the respective
measuring.

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 MotorAnalyzer-Class
Motor Repair
All control elements and connections are clearly arranged Large and high-contrast color display

PrintCom RESULTS

PrintCom – filing and printing test

results in Excel®

With PrintCom you can protocol

and store your test results quickly
and comfortably:
• scanning test results
• storing test results in Excel®
• printing test results

For detailed information please look at page 68

Scanning and storing test results in Excel® Printing test results

inspection test of a pump motor

25
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 The MotorAnalyzer-Class
MotorAnalyzer 2 | 11 test methods in one tester
1 Automatic analysis 4 Inductivity test

For the automatic test of a three-phase current motor the three The inductivity test is also performed in four-wire technology like
winding connections and the motor cabinet have to be connected the resistance test. The symmetry evaluation of the three winding
to the tester. The MotorAnalyzer analyzes the motor fully inductivities or the comparison to a preset value is performed
automatically via the resistance, inductivity, the surge-voltage, automatically.
and the high-voltage test. It checks whether the winding is
ohmically or inductively symmetrical. If the deviations of the three 5 High-voltage test DC
phases among each other are too large the motor is defect. In
addition the electric strength within the winding and to the motor’s
cabinet is tested.

2 Surge test up to 3000V

For the high-voltage test the MotorAnalyzer generates a very

For the inductive winding check the MotorAnalyzer generates
surge pulses up to 3000V that can be continuously adjusted. The
patented automatic surge voltage comparison of the windings
among each other or to a reference test object provides precise
statements regarding the winding’s symmetry. The MotorAnalyzer
detects any nonsymmetries automatically.
stable test voltage from 50 to 6000V DC. At the automatic test the
voltage is max. 3000V and at the manual test it is max. 6000V due
to the test probes. The voltage can be set manually at the rotary
button. Alternatively it can also be set automatically to a
programmable value. A step voltage measuring is possible as well.
6 Insulation resistance test

3 Resistance test

For the insulation resistance test the MotorAnalyzer generates a

very stable test voltage from 50 to 6000V DC. At the automatic test
the voltage is max. 3000V and at the manual test it is max. 6000V
The resistance test is performed with very high precision in four- due to the test probes. The voltage can be set manually at the
wire technology. The symmetry evaluation of the three winding rotary button. Alternatively it can also be set automatically to a
resistances or the comparison to a preset value is performed programmable value. A step voltage measuring is possible as well.
automatically. A temperature compensation converts the copper
resistance to 20°Celsius if required. For the ambient temperature
measuring an ambient temperature sensor has to be connected to
the Motor Analyzer.

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 7 Polarization index test 10 PE-resistance test

For the DAR and polarization index test the MotorAnalyzer The PE-resistance test is performed with high precision in

MotorAnalyzer-Class
generates a very stable test voltage from 50 to 6000V DC. The four-wire technology. It is measured with DC.
voltage can be set manually at the rotary button. Alternatively
it can also be set automatically to a programmable value. The
measuring time runs automatically.

Motor Repair
8 Neutral zone setting 11 Rotary field test

The graphic display of the brush holder’s false position facilitates
the adaptation of the “neutral zone” to direct current motors. Via a
bar display with central point the user can directly see whether he
is in the neutral zone or in which direction the brush holder needs
to be turned.
At one- or three-phase motors it is displayed during the manual
rotation of the motor shaft whether the shafts rotates to the left- or
right-hand side.

9 Turn-to-turn fault location

By means of the induction test probe the operator locates the slots
in which the turn-to-turn fault occurred. The probe also serves
for measuring at the stator, an armature, or for searching the bar
break at a squirrel-cage motor.

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 The MotorAnalyzer-Class
MotorAnalyzer 1 | All-purpose electric motor tester

USB
RS232
PC
I/O

The MotorAnalyzer is an all-purpose tester for testing electric mo-

Highlights tors and winding products. It combines ten different test methods
• ten test methods in a user-friendly, mobile tester. The combination of test methods,
• high-voltage up to 4KV its very compact design, as well as the option of a battery opera-
tion turn the MotorAnalyzer into an ideal tool for the at-site use –
• fully automatic fault analysis
especially at difficult installation positions.
• automatic switchover between the three motor connecting leads
• manual and automatic tests
For checking the three-phase current motor the three winding con-
• location of turn-to-turn-faults nections as well as the motor cabinet are connected to the tester.
• mains and/or battery operation Afterwards the MotorAnalyzer analyzes the motor automatically
• low weight via the surge and resistance test. After this a high-voltage test is
• can also be supplied in a sturdy measuring box also performed at the motor in order to evaluate the motor’s quality
• rotary button for a quick test method selection quickly and clearly.
• integrated result storage for a later transfer via RS232- or
USB-interface
• storing and printing of test results via PrintCom

Search of a turn-to-turn fault at a stator with induction test probe

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 MotorAnalyzer-Class
Motor Repair
MotorAnalyzer 1-portable

PrintCom RESULTS

PrintCom – filing and printing test

results in Excel®

With PrintCom you can protocol

and store your test results quickly
and comfortably:
• scanning test results
• storing test results in Excel®
• printing test results

For detailed information please look at page 68

Scanning and storing test results in Excel® Printing test results

Motor test MotorAnalyzer 1 with stator size 350

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 The MotorAnalyzer-Class
MotorAnalyzer 1 | 10 test methods in one tester
Isolationswiderstand Schutzleiterwiderstand
insulation resistance 6 7 PE-resistance
Polarisation
PI/DAR 5 8 Neutrale Zone
neutral zone

Hochspannung 4 Drehfeldrichtung
9 rotary field direction
high-voltage

Widerstand 3 Feldstärkenmessung
resistance field strength measuring

surge test 2 10 Windungsschluss

turn-to-turn fault

Auto. Test 1 Setup

1 Automatic analysis 3 Resistance test

1 3

For the automatic test of a three-phase current motor the three
winding connections and the motor cabinet are connected to the
tester. Afterwards the MotorAnalyzer analyzes the motor fully
automatically via the surge and resistance test. It checks whether
the winding is ohmically or inductively symmetrical. If the
deviations of the three phases among each other are too large
the motor is defect.
The resistance test is performed with high precision in four-wire
technology. The symmetry evaluation of the three winding
resistances or the comparison to a preset value is performed
automatically. A temperature compensation converts the copper
resistance to 20°Celsius if required.

2 Surge test

4 High-voltage test DC

For the inductive winding check the MotorAnalyzer generates

surge voltages with a low level. The patented automatic surge
voltage comparison of the windings among each other or to a
reference test object provides precise statements regarding the
winding’s symmetry. The MotorAnalyzer detects any
nonsymmetries automatically.
4
For the high-voltage test the MotorAnalyzer generates a very
stable test voltage from 50 to 4000V DC. The voltage can be set
manually at the rotary button. Alternatively it can also be set
automatically to a programmable value.

30
 5 Polarization index test
5 8
For the DAR and polarization index test the MotorAnalyzer
generates a very stable test voltage from 50 to 4000V DC. The
voltage can be set manually at the rotary button. Alternatively it
can also be set automatically to a programmable value.
6 Insulation resistance test
6
6
For the insulation resistance test the MotorAnalyzer generates a
very stable test voltage from 50 to 4000V DC. The voltage can be
set manually at the rotary button. Alternatively it can also be set
automatically to a programmable value. A step voltage measuring
is also possible.
7 PE-resistance test
The PE-resistance test is performed with high precision in
four-wire technology. It is measured with DC.
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8 Neutral zone setting
The graphic display of the brush holder’s false position facilitates
the adaptation of the “neutral zone” to direct current motors. With
the MotorAnalyzer it can thus be adjusted in a very user-friendly
MotorAnalyzer-Class
way. Via a bar display with central point the user can directly see
whether he is in the neutral zone or in which direction the brush
rocker needs to be turned.
Motor Repair
9 Rotary field test
At one- or three-phase motors it is displayed during the manual
rotation of the motor shaft whether the shafts rotates to the left- or
right-hand side.
10 Turn-to-turn fault location
10
By means of the induction test probe the slots at the stator or arma-
ture are located in which the turn-to-turn fault occurred. The probe
also serves for searching the bar break at a squirrel-cage motor.
31
 The MotorAnalyzer-Class
MotorAnalyzer 1 and 2 | Product and accessory overview

MotorAnalyzer 1 MotorAnalyzer 1 portable MotorAnalyzer 2

resistance surge voltage turn-to-turn inductivity high voltage insulation

faults DC resistance
KV
KV
Ω H mA
GΩ
GΩ

1mΩ…500KΩ low-voltage, fault locating of 0…100GΩ

four-wire surge voltage & the turn-to-turn
measuring autom. analysis fault

Model art. no.

MotorAnalyzer 1 403101 1 12V 2 0…4KV 3 0…4KV DC
MotorAnalyzer 1 portable 403141 1 12V 2 0…4KV 3 0…4KV DC
MotorAnalyzer 2 403167 1 3000V 2 0…6KV 3 0…6KV DC

Test probes | measuring leads

4-wire measuring tips for armatures 4000395
4-wire Kelvin tongs set 40001100
4-wire Kelvin tongs small 4007209
4-wire Kelvin tongs medium 4007212
4-wire Kelvin tongs large 4007168
temperature sensor for the 403109
ambient temperature compensation
turn-to-turn fault test probe 9mm 403106
turn-to-turn fault test probe 19mm 403107
turn-to-turn fault armature test probe 403123
Giga-Ohm measuring lead 403110
neutral zone measuring lead 403102
rotary field test probe for stator 403103
rotary field test probe for motor 403112

Accessories
foot switch 4010611
start buttons for test probe 403111
transport box for MA 1 403124
Netbook-holder for MA1-portable 403149
PrintCom PC-software 401871

For accessories please look at page 66

32
 MotorAnalyzer-Class
four-wire measuring tips four-wire Kelvin tongs turn-to-turn fault test probe Netbook holder

polarization neutral zone sense of rotation PE resistance switch-over matrix

test methods

Motor Repair
mΩ

1 .......... X

0…4000V DC comparison measuring at 1mΩ…1Ω automatic clamps: measuring lead measuring lead battery operation
assistance for the stator and motor four-wire test method U-V-W-body with alligator with test tips for
neutral zone at measuring switchover high-voltage clamps the high-voltage
DC-motors

3 0…4KV DC 4 5 7 2
3 0…4KV DC 4 5 7 2
3 0…6KV DC 4 5 6 7 2

included in the delivery extent

1 For increasing the measuring accuracy at resistances below 1Ω it is recommended to use four-wire Kelvin tongs in addition.
2 For locating the turn-to-turn fault an additional probe is required.
3 In order to measure insulation resistances above 100Ω more precisely an additional GigaOhm-measuring lead is recommended.
4 For connecting the DC-motor an additional measuring lead is required.
5 For measuring the sense of rotation one additional probe is required for the stator measuring and one additional measuring lead for the motor measuring is required.
6 Switchover automatically up to 3KV. High-voltage test up to 6KV via separate test tips.
measuring probes | measuring leads that need to be ordered in addition
not available

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66
 Motor Repair
Electrical Engineering
Maintenance

Software & Accessories

PrintCom Software .............................................................. 68

Lead Contactings ................................................................ 70
Test Pistols, Test Probes, Safety Accessories ................ 72
Rolling Tables ...................................................................... 74
Black Boxes ......................................................................... 76

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 Software & Accessories
PrintCom | Software for MotorAnalyzer, GLP1 & GLP2

PrintCom RESULTS

RS232
Ethernet
USB
Print

Archive and print test results in Excel®

Highlights
PrintCom – the quickest and most comfortable way of protocolling
• importing test results during the test and from the tester’s
and storing test results of MotorAnalyzer, GLP1- and GLP2-
intermediate storage high-voltage testers.
• storage of test results in the Excel® format during the
production Importing
• print of test results in Excel® via protocol samples
• several ready-made protocol samples included in the The software lists imported test results well-arranged on your
delivery extent computer screen.
• freely confi gurable Excel® protocol samples to print test results
• different storage modes (single or collection results) Storing
• OpenOffi ce®-/MS Excel® compatible software
The test results are user-friendly stored in the Excel® format. The
• Windows 7® compliant
basis are Excel® protocol samples preconfigured by us.

PrintCom offers you to adapt the protocol to you requirements by

adding additional information or by means of an individual protocol
layout, for example with your logo. In the delivery extent you will
already find a large variety of easily adaptable samples. Of course,
you can also create completely new protocols.

Printing

Owing to the integration of the test results in an Excel® file you are
able to print your test results directly. Thus you can impressively
document the tested quality to your customer.

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 Connecting versions

Software & Accessories

PC

Motor Repair
RS232 / USB

PC Server

Test Protocol
RS232 / USB Ethernet

PrintCom with MotorAnalyzer

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 Software & Accessories
Lead Contactings
Highlights
• various standard contactings
• mechanical solid and persistent design
• four-wire contactings – Kelvin clamps
• customized solutions based on our standard solutions
• fast exchange of consumables
70
A typical task is the contacting of stripped line ends because
test objects are often only equipped with line ends without a plug
connection.
For contacting free line ends we can provide a wide range of
clamp devices, for example for the application of stators’ winding
connections. They can be equipped in two- as well as four-wire-
technology.
When low resistances are to be exactly measured Kelvin clamps
are used for the four-wire-measuring. The four-wire-technology
compensates the transition resistances within the clamping points.
Our Kelvin clamps’ special design guarantees high contact
reliability, solid clamping, and a low wear and tear in the rough
testing operation. Less exacting contactings are operated with our
multi-purpose clamping levers.
The contactings can be supplied as loose single contacting or
integrated within a clamp block. The clamp blocks can either be
assembled in a fixed position within the test cover or can be moved
flexibly within the testing space to always have the optimum
position for being clamped to the lines.
Examples for Kelvin clamps, clamping levers, and modular contact blocks

Software & Accessories

clamp block in modular design clamp block in modular design

Motor Repair
Kelvin clamps in small-, medium-, and large-sized design 8-times Kelvin clamps block

Kelvin contacting in one test cage with prism

11-times clamping lever block 6-times four-wire contacting guide and 4-times clamping lever block

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 Software & Accessories
Test Pistols | Test Probes | Safety Accessories

High-voltage

Safety pistols are required for a safe manual high-voltage test.

Depending on the test voltage level there are different models.

To achieve a particular high usability we provide test pistols with

an integrated start button. Here the high-voltage test only starts
after activating the button.

high-voltage test pistol up to high-voltage test pistol up to

8KV AC/10KV DC 12KV AC/15KV DC

high-voltage test pistol without start button

high-voltage test probe up to 1500V

high-voltage test pistol with start button safety current limited

adaptor between test object and

test pistol

high-voltage test pistol with start through mechanical

press button
high-voltage connection lead

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 Software & Accessories
Motor Repair
Warning- result lights Safety

Warning lights show whether the test object is under voltage or
voltage-free.
Result lights show the total test result of the test process.
Customized special displays, which can also be controlled by the
tester, are also within our product range.
Due to safety reasons a two-hand start is used at the high-voltage
test without protection cover and safety test pistols. When
operating test stations the corresponding standards have to be
considered.

two-hand start two-hand start support with

warning light and emergency stop
warning or result light, horizontal warning or result light, vertical

safety barrier with warning barrier post with warning light and
message emergency stop

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 Software & Accessories
Rolling Tables

Rolling tables facilitate the transport of testers that can also be

Highlights combined with a test cover between the test objects. A high level
usability is achieved by the large, high-resistant and lockable
• solid design made of aluminum profi les
rubber guide rollers as well as an optional push handle at the
• continuously height adjustable table plates and bottoms table’s front.
• horizontal or diagonal table plate designs
• diagonal table plate with horizontal front e.g. to deposit a The rolling tables can additionally be equipped with self-closing
keyboard drawer runners, in which e.g. adaptors, tools, or documentations
• continuously height adjustable drawers with full extension can be stored.
• continuously height adjustable holder for test probe
• continuously height adjustable windings for measuring leads
• integrated LED-warning light in the side rails
• delivery of assembled, directly usable rolling tables
• rolling tables and carriages of the company hera

rolling table with horizontal work rolling table with horizontal work
plate and push handle plate, push handle and a LED
warning light integrated in the bars

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 Software & Accessories
Motor Repair
rolling table with diagonal work rolling table with diagonal work rolling table with diagonal work
plate and integrated high-voltage plate and drawer element plate, drawer element and cable
test holders

rolling table with integrated test cover, push handle, LED-warning light in rolling table with integrated test
the bars and holders for cables, test pistols, and test probes cover, drawer element and cable
holders

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 Software & Accessories
Black Boxes
black box for PE
back box HV for test pistols
calibration resistor in
four-wire-technology
calibration resistor
high-voltage proof
76
black box for PE | IR | HV
high-current calibration resistor in
four-wire-technology
Black Boxes
For a regular daily check of your tester a black box is used that
is connected to the tester. It is tested whether the emerging
measuring values correspond to the values in the black box. If this
is not the case the tester is locked. The tester can only be used
again when a black box test with a proper result is performed. As
we only supply digital evaluating testers this test is normally not
performed with a “pass-fail-black box”. We only use one single
black box and evaluate the emerging measuring values within tight
tolerance limits.
Each black box consists of one connection possibility to the tester
and one or several resistors and/or inductances. They can either
be configured for one test method or for a combination of several
test methods.
Each black box is delivered with the information on the resistance
values and a calibration certificate so that the operator can set the
tests properly.
Calibration resistors
For the calibration of testers precise calibration resistors are
required as well. They make sure that certain test currents flow at
different test methods and voltages.
The calibration resistors have a high precision as well as a high
temperature and long-term stability. In order to conduct the heat
that occurs at high currents or long measurings, reliably, we supply
all calibration resistors for high test currents in special heat sink
enclosures. In addition to these characteristics the resistors are
designed low capacitively and low inductively.
All resistors for high test currents and low test voltages are
designed in four-wire-technology.
All resistors are supplied with the information on the resistance
values in the calibration certificate so that the corresponding
conversions of the measuring values considering the resistance
value are possible.